Audi 100/A6
+ 1. Maintenance instruction
+ 2. Maintenance
+ 3. Engines
+ 3.2. Diesel engines
- 3.3. Removal and partition of engines
- 3.3.2. Technical characteristics
3.3.2.2. Inhaling moments
3.3.3. Repair work, possible without engine dismantle
+ 3.3.4. Major maintenance
3.3.5. Removal and engine installation
3.3.6. Engine partition
+ 3.3.7. Head of cylinders
3.3.8. Pistons and rods
+ 3.3.9. Cranked shaft
3.3.10. Intermediate shaft
3.3.11. Block of cylinders
3.3.12. Radical bearings and bearings of rods
3.3.13. Piston rings
3.3.14. The first start of the engine after a partition
+ 4. Cooling system
+ 5. Heating and ventilation
+ 6. Fuel system
+ 7. Exhaust system
+ 8. Systems of start, ignition
+ 9. Transmission
+ 10. Brake system
+ 11. Suspension brackets, steering
+ 12. Body
+ 13. Electric equipment
+ 14. Good advice
|
Codes of engines
|
4-cylinder petrol engines
|
| 1781 cm3, injector system Bosch Motronic 3.2, 92 of kW |
ADR
|
| 1984 cm3, injector system Bosch Mono-Motronic, 74 kW |
AAE
|
| 1984 cm3, injector system Bosch KE-Motronic, 103 kW |
ACE
|
| 1984 cm3, injector system Volkswagen Digifant, 85 kW |
ABK
|
| 1984 cm3, injector system Bosch KE-Motronic, 85 kW |
AAD
|
|
5-cylinder petrol engines
|
| 2226 cm3, injector system Motronic, 169 kW |
AAN
|
2309 cm3, injector system Bosch KEIII Jetronic, 98 kW
|
AAR
|
|
4-cylinder diesel engine
|
| 1896 cm3, direct injection, turbo-supercharging, 66 kW, 1Z |
AHU
|
|
5-cylinder diesel engines
|
| 2370см3, direct injection, normal absorption, 64 kW |
AAS
|
| 2460см3, direct injection, turbonagnetatel, 85 kW, ABP |
AAT
|
| 2460см3, direct injection, turbonagnetatel, 103 kW |
AEL
|
|
Head of cylinders
|
| Maximum deformation of a surface of a head of cylinders: |
| All types of engines except diesel engines AAS, AAT, ABP, AEL |
0,1 mm
|
| Diesel engines AAS, AAT, ABP, AEL |
0,2 mm
|
| Minimum height of a head of cylinders: |
| Petrol ADR engine |
139,25 mm
|
Petrol AAE, ABK, AAD
|
132,6 mm
|
| Petrol ACE, |
118,1 mm
|
| Petrol AAR, AAN |
132,75 mm
|
| Diesel engines |
Repeated processing is impossible
|
| Selection of laying of a head of cylinders (diesel engine 1Z, AHU): |
| Piston 0,91 ledge – 1,00 mm |
1 opening
|
| Piston 1,01 ledge – 1,10 mm |
2 openings
|
| Piston 1,11 ledge – 1,10 mm |
3 openings
|
| Selection of laying of a head of cylinders (AAS diesel engine): |
| Piston 0,66 ledge – 0,86 mm |
1 opening (thickness of 1,53 mm)
|
| Piston 1,01 ledge – 1,10 mm |
2 opening (1,57 mm)
|
| Piston 1,11 ledge – 1,20 mm |
3 opening (1,61 mm)
|
| Selection of laying of a head of cylinders (diesel engine of ABP, AAT, AEL): |
Piston 0,76 ledge – 0,01 mm
|
1 opening (thickness of 1,53 mm)
|
Piston 1,02 ledge – 1,05 mm
|
2 opening (1,57 mm)
|
Piston 1,06 ledge – 1,13 mm
|
3 opening (1,61 mm)
|
| The minimum distance from the center of a rod of the valve to a head surface: |
Inlet valve / Final valve
|
| – Petrol ADR |
33,2 mm / 33,0 mm
|
| – Petrol AAE, ABK, AAD, AAR, AAN |
33,8 mm / 34,1 mm
|
| – Petrol ACE |
34,4 mm / 34,7 mm
|
| – Diesel engines |
35,8 mm / 36,1 mm
|
|
Pistons and piston rings
|
| Diameter of the piston: |
| – Petrol ADR: |
| The standard |
80,985 mm
|
| Increased, after the first boring of the cylinder |
81,235 mm
|
| Increased after the second boring |
81,485 mm
|
| Maximum deviation |
0,04 mm
|
| – Petrol AAE, ACE, ABK, AAD, AAR, AAN: |
The standard
|
82,480 mm
|
| Increased, after the first boring of the cylinder |
82,730 mm
|
| Increased after the second boring |
82,980 mm
|
| Maximum deviation |
0,04 mm
|
| – Diesel engine 1Z, AHU: |
| The standard |
79,170 mm
|
| Increased, after the first boring of the cylinder |
79,720 mm
|
| Increased after the second boring |
79,970 mm
|
| Maximum deviation |
0,04 mm
|
| – AAS diesel engine: |
| The standard |
79,480 mm
|
| Increased, after the first boring of the cylinder |
79,730 mm
|
| Increased after the second boring |
79,980 mm
|
| Maximum deviation |
0,04 mm
|
| – Diesel engine of ABP, AAT, AEL: |
| The standard |
80,960 mm
|
| Increased, after the first boring of the cylinder |
81,210 mm
|
| Maximum deviation |
0,04 mm
|
| Gap between piston rings and flutes of rings: |
| 4 cylinders, petrol ADR: |
| – New: |
| Kompressionnye of a ring |
0,02-0,07 mm
|
| Maslosjemnoye ring |
0,02-0,06 mm
|
| Maximum wear |
0,12 mm
|
| 4 cylinders, petrol AAE, ABK, AAD: |
| – New: |
|
| Kompressionnye rings and maslosjemny ring |
0,02-0,50 mm
|
| Maximum wear |
0,15 mm
|
| 4 cylinders, petrol ACE: |
| – New: |
| Kompressionnye of a ring |
0,02-0,07 mm
|
| Maslosjemnoye ring |
0,02-0,06 mm
|
| Maximum wear |
0,15 mm
|
| 5 cylinders, petrol AAR, AAN: |
| – New: |
Kompressionnye of a ring
|
0,02-0,07 mm
|
| Maslosjemnoye ring |
0,02–0,06 mm
|
Maximum wear
|
0,12 mm
|
| 4 cylinders, diesel engine 1Z, AHU: |
| – New: |
| Top kompressionny ring |
0,06-0,09 mm
|
| Second kompressionny ring |
0,05-0,08 mm
|
| Maslosjemnoye ring |
0,03-0,06 mm
|
| Maximum wear: |
| Kompressionnye of a ring |
0,25 mm
|
| Maslosjemnoye ring |
0,15 mm
|
| 5 cylinders, AAS diesel engine: |
| – New: |
| Top kompressionny ring |
0,09-0,12 mm
|
| Second kompressionny ring |
0,05-0,08 mm
|
| Maslosjemnoye ring |
0,03-0,06 mm
|
| Maximum wear: |
| Kompressionnye of a ring |
0,25 mm
|
| Maslosjemnoye ring |
0,15 mm
|
| 5 cylinders, AAT diesel engine: |
| – New: |
| Top kompressionny ring |
0,07-0,105 mm
|
| Second kompressionny ring |
0,05-0,075 mm
|
| Maslosjemnoye ring |
0,03-0,065 mm
|
| Maximum wear: |
| Kompressionnye of a ring |
0,25 mm
|
| Maslosjemnoye ring |
0,15 mm
|
| Pistons and piston rings (continuation) |
|
Trailer gaps of piston rings
|
| 4 cylinders, petrol ADR: |
| – New: |
Kompressionnye of a ring
|
0,15-0,40 mm
|
| Maslosjemnoye ring |
0,25-0,50 mm
|
| Ring from 3 parts |
less than 1,00 mm
|
| Maximum wear: |
| Kompressionnye of a ring |
0,80 mm
|
| Maslosjemnoye ring |
1,0 mm
|
| Ring from 3 parts |
1,30 mm
|
| 4 cylinders, petrol AAE, ABK, AAD: |
| – New: |
| Kompressionnye of a ring |
0,30–0,45
|
| Maslosjemnoye ring |
0,25-0,45 mm
|
| Maximum wear |
1,0 mm
|
| 4 cylinders, petrol EXPERT: |
| – New: |
| Kompressionnye of a ring |
0,20-0,40 mm
|
| Maslosjemnoye ring |
0,2-0,50 mm
|
| Maximum wear |
1,0 mm
|
| 5 cylinders, petrol AAR, AAN: |
| – New: |
Kompressionnye of a ring
|
0,02-0,07 mm
|
| Maslosjemnoye ring |
0,02-0,06 mm
|
| Maximum wear |
0,15 mm
|
| 4 cylinders, diesel engine 1Z, AHU: |
| – New: |
| Kompressionnye of a ring |
0,20-0,40 mm
|
| Maslosjemnoye ring |
0,25-0,50 mm
|
Maximum wear
|
1,0 mm
|
| 5 cylinders, AAS diesel engine: |
| – New: |
Kompressionnye of a ring
|
0,20-0,40 mm
|
Maslosjemnoye ring
|
0,25-0,50 mm
|
| Maximum wear: |
| Top kompressionny ring |
1,20 mm
|
| Second kompressionny ring |
0,60 mm
|
| Maslosjemnoye ring |
1,20 mm
|
| 5 cylinders, diesel engine of ABP, AAT, AEL: |
| – New: |
| Top kompressionny ring |
0,25-0,45 mm
|
| Second kompressionny ring |
0,20-0,40 mm
|
| Maslosjemnoye ring |
0,25-0,50 mm
|
| Maximum wear |
1,0 mm
|
|
Valves
|
| Diameter of a rod of the valve: |
| The inlet: |
| ADR |
5,95-5,97 mm
|
| AAE, ABK, AAD, AAR, 1Z, AHU, AAS, ABP, AAT, AEL, AAN |
7,97 mm
|
| ACE |
6,97 mm
|
| The final: |
| ADR |
5,94-5,95 mm
|
| AAE, ABK, AAD, AAR, 1Z, AHU, AAS, ABP, AAT, AEL, AAN |
7,95 mm
|
| ACE |
6,94 mm
|
| Maximum deviation of a head of the valve: |
| The inlet: |
| ADR |
0,8 mm
|
| AAE, ACE, ABK, AAD, AAR, AAN |
1,0 mm
|
| 1Z, AHU, AAS, ABP, AAT, AEL |
1,3 mm
|
| The final: |
| ADR |
0,8 mm
|
| AAE, ACE, ABK, AAD, AAR, AAN |
1,3 mm
|
| 1Z, AHU, AAS, ABP, AAT, AEL |
1,3 mm
|
|
Camshaft
|
| Maximum free wheeling: |
| The inlet: |
| AAE, ACE, ABK, AAD, AAR, 1Z, AHU, AAS, ABP, AAT, AEL, AAN |
0,15 mm
|
| ADR |
0,20 mm
|
| Palpation (all types) |
0,01 mm
|
Maximum lubricant gap (all models)
|
1,10мм
|
|
Intermediate shaft
|
| Maximum free wheeling: |
| ADR, AAE, ACE, ABK, AAD, 1Z, AHU |
0,25 mm
|
|
Block of cylinders
|
| Diameter of the cylinder: |
| ADR: |
| The standard |
81,01 mm
|
| Increased, after the first boring |
81,26 mm
|
| Increased, after the second boring |
81,51 mm
|
| Maximum wear of the cylinder |
0,10 mm
|
| AAE, ACE, ABK, AAD, AAR, AAN: |
| The standard |
82,51 mm
|
| Increased, after the first boring |
82,76 mm
|
| Increased, after the second boring |
83,01 mm
|
| Maximum wear of the cylinder |
0,08 mm
|
| 1Z, AHU, AAS: |
| The standard |
79,51 mm
|
| Increased, after the first boring |
79,76 mm
|
| Increased, after the second boring |
80,01 mm
|
| Maximum wear of the cylinder: |
| 1Z, AHU |
0,10 mm
|
| AAS |
0,08 mm
|
| ABP, AAT, AEL: |
| The standard |
81,01 mm
|
| Increased, after the first boring |
81,26 mm
|
| Maximum wear of the cylinder |
0,08 mm
|
|
Rods
|
| Lateral gap of the bottom head of a rod: |
| AAE, ACE, ABK, AAD, 1Z, AHU |
0,37 mm
|
| ACE, AAR, AAS, ABP, AAT, AEL, AAN |
0,4 mm
|
|
Cranked shaft
|
Depth of the aligning needle bearing
|
1,5 mm
|
| Free wheeling: |
| Face value: |
| Petrol ADR, AAR, AAN |
0,07-0,23 mm
|
| Petrol AAE, ABK, AAD |
0,017-0,17 mm
|
| Petrol ACE |
0,07-0,17 mm
|
| Diesel engine 1Z, AHU |
0,07-0,17 mm
|
| Diesel engine of AAS, ABP, AAT, AEL |
0,07-0,18 mm
|
| Maximum wear: |
| Petrol ADR |
0,30 mm
|
| Petrol AAR, AAN |
0,25 mm
|
| Petrol AAE, ABK, AAD, ACE |
0,25 mm
|
| Diesel engine 1Z, AHU |
0,37 mm
|
| Diesel engine of AAS, ABP, AAT, AEL |
0,25 mm
|
| Lubricant gap of the radical bearing: |
| Petrol ADR, AAE, ACE, ABK, AAD |
0,17 mm
|
| Petrol AAR, AAN |
0,10 mm
|
| Diesel engine 1Z, AHU |
0,17 mm
|
| Diesel engine of AAS, ABP, AAT, AEL |
0,16 mm
|
| Diameter of a neck of the radical bearing: |
| 4 cylinders, petrol ADR, AAE, ACE, ABK, AAD: |
| The standard |
54,00 mm
|
| Reduced, after the first grinding |
53,75 mm
|
| Reduced, after the second grinding |
53,50 mm
|
| Reduced, after the third grinding |
53,25 mm
|
| 5 cylinders, petrol AAR, AAN: |
| The standard |
58,00 mm
|
| Reduced, after the first grinding |
57,75 mm
|
| Reduced, after the second grinding |
57,50 mm
|
| Reduced, after the third grinding |
57,25 mm
|
| 4 cylinders, diesel engine 1Z, AHU: |
| The standard |
54,00 mm
|
| Reduced, after the first grinding |
53,75 mm
|
| Reduced, after the second grinding |
53,50 mm
|
| Reduced, after the third grinding |
53,25 mm
|
| 5 cylinders, diesel engine of AAS, ABP, AAT, AEL: |
| The standard |
58,00 mm
|
| Reduced, after the first grinding |
57,75 mm
|
Reduced, after the second grinding
|
57,50 mm
|
| Reduced, after the third grinding |
57,25 mm
|
| Diameter of a neck of a rod: |
| All engines: |
| The standard |
47,80 mm
|
| Reduced, after the first grinding |
47,55 mm
|
| Reduced, after the second grinding |
47,30 mm
|
| Reduced, after the third grinding |
47,05 mm
|
Maximum ovality
|
0,03 mm
|
|
|
